AC/DC MULTI-200P AC/DC MULTI-220P
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1 THANKS FOR PURCHASING OUR PRODUCT AC/DC MULTI-200P AC/DC MULTI-220P DC INVERTER AC TIG/DC TIG/DC MMA/CUT 4 IN 1 MACHINE OPERATION INSTRUCTIONS
2 SAFETY PRECAUTIONS Follow these precautions carefully. Improper use of any welder can result in injury or death. 1. ONLY CONNECT WELDER TO A POWER SOURCE FOR WHICH IT WAS DESIGNED. The specification plate on the welder lists this information. When welding outdoors, only use an extension cord intended for such use. 2. ONLY OPERATE WELDER IN DRY LOCATIONS and on concrete floor. Keep area clean and uncluttered. 3. KEEP ALL COMBUSTIBLES AWAY FROM WORK SITE. 4. DO NOT WEAR CLOTHING THAT HAS BEEN CONTAMINATED with grease or oil. 5. KEEP CABLES DRY AND FREE FROM OIL AND GREASE and never coil around shoulders. 6. SECURE WORK WITH CLAMPS or other means; don't over reach when working. 7. NEVER STRIKE AN ARC ON A COMPRESSED GAS CYLINDER 8. DON'T ALLOW THE INSULATED PORTION OF THE ELECTRODE HOLDER TO TOUCH THE WELDING GROUND WHILE CURRENT IS FLOWING. 9. SHUT OFF POWER AND UNPLUG MACHINE WHEN REPAIRING OR ADJUSTING. Inspect before every use. Only use identical replacement parts. 10. FOLLOW ALL MANUFACTURER'S RULES on operating switches and making adjustments. 11. ALWAYS WEAR PROTECTIVE CLOTHING when welding. This includes: long sleeved shirt (leather sleeves), protective apron without pockets, long protective pants and boots. When handling hot materials, wear asbestos gloves. 12. ALWAYS WEAR A WELDER'S HELMET WITH PROTECTIVE EYE PIECE when welding. Arcs may cause blindness. Wear a protective cap underneath the helmet. 13. WHEN WELDING OVERHEAD, BEWARE OF HOT METAL DROPPINGS. Always protect the head, hand, feet and body. 14. KEEP A FIRE EXTINGUISHER CLOSE BY AT ALL TIMES. 15. DO NOT EXCEED THE DUTY CYCLE OF THE MACHINE. The rated cycle of a welding machine is the percentage of a ten minute period that the machine can operate safely at a given output setting. 16. KEEP ALL CHILDREN AWAY FROM WORK AREA. When storing equipment, make sure it is out of reach of children. 17. GUARD AGAINST ELECTRIC SHOCK. Do not work when tired. Do not let body come in contact with grounded surfaces.
3 I. MAIN USAGE AND THE RANGE OF USAGE AC/DC MULTI-220P Welder is a triple functional machine used as DC MMA, AC TIG, DC/PULSE TIG Welder. All ferrous metals, copper, aluminium, titanium and stainless steel material can be welded from all positions. The welding current is stable and the stepless is adjustable. Few spatter and low noise occurs during welding. The welder is compact, light in weight and easy to move. It is suitable for pressure vessel, building, shipping and petrochemical industries. It is the priority product to replace the NSA series welding machine. MAIN TECHNICAL SPECIFICATIONS MODEL AC/DC MULTI-220P AC/DC MULTI-200P INPUT Voltage AC220/230/ 240V 50Hz No-load Voltage 60-80V AC TIG Base current Adjusting Range 20~220A 20~200A AC balance 30%~70 % AC Square Wave Frequency 20~100Hz Rated Duty Cycle 60% Pulse Current Adjusting Range 10~220A 5~200A DC Rated Duty Cycle 35% Current Down-slope Time 0~10S Base Current Adjusting Range 10~220A 5A~200A Pulse Width Ratio 0.1~0.9 TIG Pulse Frequency 0.5~25Hz After Flow Time 1~25s Arc starting Mode No-load Voltage high frequency arc striking 60-80V DC MMA Base current Adjusting Range 10~180A 5~160A Rated Output Current 180A 160A Rated Duty Cycle 35% CUT (Base) current Adjusting Range 15A~60A 15~50A Rated Duty Cycle 35% Efficiency 83% Mass Protection Class of enclosure Outline Dimensions mm 3 25kg IP21S 430x200x290
4 OPERATING CONDITIONS AND WORK SURROUNDING 1. Operating condition: Voltage of power source: AC 220/230/240 V±10% Frequency: 50/60Hz Reliable grounding protection 2. Work surrounding 1 Relative humidity: not more than 90 %( average monthly temperature not more than 20C); 2 Ambient temperature:-10c - 40C; 3. The welding site should be free of harmful gases, chemicals, molds and flammable, explosive or corrosive materials; 4. Avoid operating in damp or wet conditions Ⅳ. OPERATING INSTRUCTION 1. Before welding, the operator should read the operation instructions. 2. Check the welder appearance for any damage before operation. 3. To ensure safe operation, the welder must be grounded correctly according to your local power supply system using a 4mm 2 lead to connect the welder to the ground. 4. Welding operation should be carried out in dry and well ventilated areas and conditions. Surrounding objects should not be less than 0. 5m away from the welder. 5. Check the welder output connector for tightness. 6. The welder cannot be moved and the cover cannot be opened while the power is on and welding operation is carried out. 7. The welder should be cared for, used and managed by trained personnel. 8. Current of the distribution board: not less than 40A SKETCH THE PANEL FUNCTION 1. FRONT PANEL 2. BACK PANEL
5 1. Indication of welding current 2. Power switch 3. Pulse current regulator 4. Base current regulator 5. Pulse width regulator 6. Pulse Freq. regulator 7. Indicating light of power 8. Warning indicating light 9. Current up-slope time regulator 10. Current down-slope time regulator 11. Post flow time regulator 12.MMA/TIG/ CUT switch 13. AC balance 14. output"+" 15. AC square wave Frequency 16. Arc force 17. Argon out 18. Argon arc control (or remote control) 19. AC/DC TIG switch 20. Output"-" 21. Argon inlet 22. Power supply 23. Nameplate 24. Fan 25. Safety earthing column steps/ 4 steps switch 27. Pilot arc METHOD OF THE OPERATION 1.ARGON ARC WELDING(TIG) a. FRONT OF WELDER b. BACK OF WELDER Valve argon bottle flow meter gas inlet pipe torch oo
6 1.1 CLEAN BEFORE WELDING Tungsten argon welding is very sensitive to surface contamination. Therefore ensure material is clean and free from all contaminants including grease, paint, lubricants and rust. Use an appropriate pre-cleaner if necessary. 1.2 DC ARGON ARC WELDING 1Put Switch "19" (AC/DC) onto the position "DC", connecting the gas inlet pipe to inlet "21" of the welding. Put switch "12" (MMA/TIG/CUT switch) onto the position "TIG". 2Connect gas inlet pipe of the welder torch to argon output of welder "17". 3Put the control plug of the welding torch in the argon arc control socket "18". 4Testing gas: Switch on the power "2", open the argon bottle valve, press the torch switch, select suitable argon flow. 5Regulating the base current knob "4" (pulse current regulating to minimum, turning it anti clockwise to the end). Select welding current according to the thickness of the material to be welded. Select current down slope time and after flow time according to the current. Notice 1: The current indicating meter on the front panel is used to display the preset output current level before welding and actual output level while welding: A lit display indicates that the input power is turned on. Notice 2: When using the 'Adjustable foot control' regulator, current will increase gradually when you step on the 'Adjustable foot control' 6Ensure Tungsten electrode end is 2-3mm away from the welding material. Press the torch switch,to strike an arc. Notice 3: During welding, with the "12. 2T/4T" mode on "2T" mode, the torch trigger should be held at all times and must not be released. Otherwise the arc will extinguish. 8.When the welding operation is finished, close the valve and turn off the power. 1.3 PULSE ARGON ARC WELDING 1Select peak current and base current: 1Current regulation: To carry out the pulse argon arc welding, the base current "4" should be lower than pulse current "3" (current regulation). Rotate knob clockwise, to increase current. 2Pulse frequency regulating: when the knob "6" is regulated clockwise, the frequency is high and pulse speed is high; conversely the speed is low. The frequency changes between Hz. 3Regulation of pulse width ratio: when the knob "5" is regulated clockwise, the width ratio increases, conversely, it decreases. It can be selected between Regulation of up-slope time: when the knob "9" is regulated clockwise, the time increases. Conversely, it decreases. It can be selected between 0-10S. 5 Regulation of down-slope time: when the knob "10" is regulated clockwise, the time increases, conversely, it decreases. It can be selected between 0-10S. 6Gas connection, testing, generating and post flow time use the same procedures as DC arc welding.
7 Ib Ip 1.4 PULSE ARGON TUNGSTEN WELDING PROCESS (only for reference) ` Ip--pulse current CUR. welding process (A) Ib--base current tp tb down-slope tp--width time of pulse current gas sending in advance arcing up-slope T arcing off after flow tb--width time of base current tp+tb=t tp --- = D pulse width tb t1 T (s)
8 1Features and application scope of the process The pulse type argon tungsten welding is different from the continuous (DC) argon welding. The welding current is pulsed. The wave form of the current is shown in the sketch above. Ip and Ib and their continuous time tp and tb can be regulated according to requirements of the process. The amplitude value of electric current changes periodically with certain frequency in case of the pulse current, molten base will be formed in the work piece and the molten bath will solidify. The welding seam is formed by reciprocal overlaps. Welding heat input can be controlled by regulating pulse frequency, pulse current amplitude, size of base current, continuous time of pulse current and base current and therefore the welding seam, size and quality of the zone influenced from heat can be controlled. 2Advantages and application scope of pulse argon gas tungsten arc welding a. Precisely control the size of the bath inputting heat to the material to increase penetration resistance of molten seam and preservation of bath. It is easy to obtain even fusion deepness. b. Heating and cooling of each welding point is very fast. Therefore, the process is applicable for the material with great difference of heat conductivity and thickness. c. Pulse arc can obtain greater fusion deepness with lower heat input. Therefore under the same condition, the zone influenced from the welding heat reduces the possibility of distortion from welding. This is very important for sheet and ultra-thin sheet welding. d. Fast cooling of the bath metal and short duration time of high temperatures during welding can reduce cracks caused to the thermo-sensitive materials during welding. 3.Selection of welding parameters Except for pulse current, width time (width ratio) and pulse frequency, welding parameters of pulse argon gas tungsten arc welding are the same as general tungsten DC argon arc welding. Increasing pulse current means electric arc can obtain greater penetration ability. However, too much current can cause local melting of tungsten electrode. Generally, welding current required for DC tungsten argon arc welding uses greater current. The arc holding current and base current influences the cooling and crystallizing of the metal in the bath. The range is determined by the performance of the welding materials. When the sheet is being welded, smaller arc holding current (base current) is usually used in order to reduce the possibility of blowing holes through the sheet/material and reduce the possibility of sheet/material distortion. When pulse width ratio (holding time of pulse current and base current) is selected, both the heat input and features of pulse welding should be considered. Usually, it can be selected between 10%- 90%. Selection of pulse frequency (periodical change time of pulse current) mainly depends on the thickness of the sheet and welding speed. The customized settings of the operator should also be considered for the pulse width ratio.
9 1.5 AC ARGON ARC WELDING 1. Put switch "19" (AC/DC) onto the position "AC". 2. The method of the connection same as Regulating "13" to select right "sp(ac balance)" tp SP= tn *100% tp: the time of I 2 at positive tn: the time of In at Negative 4. Regulate "15" to select right AC square wave frequency. 5. The Method of the welding same as Hand welding with electrode 1. Connect input power for the welder, then switch on the power. The Data Display Meter ( 7 ) light will switch on. 2. Put switch"12" (MMA/TIG/CUT switch) onto the position "MMA". 3. Regulate Current Knob "4" (base current regulator) to select right welding current (Pulse current regulator to minimum, turning it anticlockwise to the end) select empiric formula: I=40d, d is dia. of the electrode. 4. Notice positive and negative connections during welding. A. NEGATIVE CONNECTION B. POSITIVE CONNECTION WELDER WELDER ELECTRODE HOLDER WORKPIECE ELECTRODE HOLDER WORKPIECE 5. Pay attention to the rated welding current and the rated duty cycle of the welder. Overload is not allowed. 6. After the welding operation is finished let the welder cool down for a few minutes before cutting off the power switch.
10 3. Cutting with compressed air Put switch"12" (MMA/TIG/CUT switch) onto the position "CUT" (1) Connect the machine correctly according to the diagram. Switch on the air compressor to its rated pressure. (2) Turn the power switch of the cutting machine on. The power indicator light will illuminate and the cooling fan will begin working. (3) Put the function switch in the position of "air testing". Then the air will expel from the cutting torch. Turning the function switch in the position of "cutting" and pressing the torch switch will also expel air from the torch. (4) Select a suitable cutting current and air pressure according to the thickness and material of the work piece and the a p p r o p r i a t e cutting speed. Select the standard for the spray nozzle of the torch. The spray nozzle will not change color while cutting. (5) Cutting: Hold the cutting torch at the edge of the work piece and position the nozzle towards the work piece at 15 degrees. Let the nozzle touch the work piece, and press the torch switch. The air will now be expelled and a high frequency arc will be generated. The high frequency can be cut off automatically after the arc generation. After the torch has pierced through the work piece, straighten the torch vertically and follow your desired cut line. Once you have finished cutting, release the trigger to extinguish the arc.
11 air compressor torch oo work SYSTEMATIC BLOCK DIAGRAM Rectifier & Inverse OUTPUT AC/DC + 220/230/240V Filter INPUT Circuit 2x25KHz Rectifier Filter OUTPUT Control Circuit H.F. TORCH -
12 This product is sold subject to the understanding that if any defects in manufacture or material shall appear within 12 months from date of consumer purchase/sale, the manufacturer will arrange for such defects to be rectified without charge on the sales invoice and warranty card (except for damage caused by neglect). General Troubles and Problem Solving: Trouble Causes Problem Solving Power lamp not lit 1.No electricity input 2. Switch of welder fails. 1.Check incoming line 2.Replace the switch 1. Fan power line is off. 1.Reconnect the line Fan not rotating 2. Enclosure blocks the fan due to distortion 2.Reform the enclosure Warning lamp lights No output of welder Output current decreased Current cannot be regulated 3. 1.Over The fan heat fails. (yellow lamp lights) 3.Replace 1. Weld after the cooling. fan 2.Over current (Green lamp lights) 2. Increase input voltage 1.Over current protection 1. Over load using 2. Welder fails 2. Maintenance in manufacturer or service 1. Input Voltage is low 1. center Power line is thickened 2. Input line is too thin 1.Connecting line of the potentiometer is off 1.Reconnect the line 2.Potentiometer for current regulation fails 2.Replace potentiometer High frequency arc cannot be generated Arc of argon welding is broken or tungsten electrode 1.The switch fails 2.Interval of high frequency discharging is too big 3.Proximity of torch and work pieces too great 1.Argon gas flow is not regulated well 2.Tungsten electrode fails 1.Replace torch switch 2.Regulate discharging interval to mm 3.Put torch tungsten electrode close to material 4.Replace high frequency arc generator 1.Regulate well 2.Replace or sharpen is burnt Welding torch overheat 3. Value of current does not match with dial. 3.Select the electrode dial and of tungsten electrode current correctly 1. Cannot use the water cooling 4.After when the flow current time is is more too short than 4.Increase the time 1.Use water cooling 160A 2.The argon flow is the low current 2.Increase the argon flow
13 ACCESSORIES: SEE PACKING LIST PLEASE PACKING LIST AC/DC MULTI200P 4 IN 1 MACHINE 1 Ground clamp 1 TIG welding torch 1 Welding holder 1 optional accessory gas inlet pipe 1 Air pressure Regulator 1 Adjustable foot control 1 optional accessory Cutting torch 1 Electrode 5 Tip Ceramic shield 3 Operation instructions 1 Certificate of quality 1 No. Certificate of quality Name of product: ACTIG/DCTIG/DC MMA/CUT 4 IN 1 MACHINE Type of product: AC/DCMULTI200P Packing No: Test results of this welder fulfills _technical requirements and its release from the works is granted. Inspector_ Date _
14 ACCESSORIES: SEE PACKING LIST PLEASE PACKING LIST AC/DC MULTI220P 4 IN 1 MACHINE 1 Ground clamp 1 TIG welding torch 1 Welding holder 1 optional accessory gas inlet pipe 1 Air pressure Regulator 1 Adjustable foot control 1 optional accessory Cutting torch 1 Electrode 5 Tip Ceramic shield 3 Operation instructions 1 Certificate of quality 1 No. Certificate of quality Name of product: ACTIG/DCTIG/DC MMA/CUT 4 IN 1 MACHINE Type of product: AC/DCMULTI220P Packing No: Test results of this welder fulfills _technical requirements and its release from the works is granted. Inspector_ Date _
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